Systems and methods for controlling an electric motor

ABSTRACT

Methods and systems for controlling an electric motor using a motor controller including a processor are provided. The method includes transmitting, by the processor, a no-spin signal commanding the electric motor not to spin, receiving temperature information associated with a temperature of the electric motor, comparing the temperature information to a predetermined threshold temperature to determine whether the temperature is at a sufficient level to prevent icing, and adjusting current applied to the electric motor when the temperature measurement is below the predetermined threshold.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.14/887,467, filed Oct. 20, 2015, the entire contents and disclosure ofwhich are hereby incorporated by reference herein.

BACKGROUND

The embodiments described herein relate generally to motors, and moreparticularly, to systems and methods for controlling an electric motor.

Electric motors are used in a variety of systems operating in a varietyof industries. Some such uses of electric motors include evaporatorand/or cold-storage applications such as walk-in freezers. Electricmotors used in such applications are exposed to freezing temperatures,for example, temperatures as low as −50° C. At such temperatures, alarge amount of condensing occurs, including continuous heating andcooling during different phases throughout the day. In some instances,an internal ambient temperature of the electric motor may reach afreezing point and ice may form within the motor's components, resultingin a potential locking environment. Moreover, if any ice formation isdefrosted too rapidly, damming and/or flooding may occur and damage theelectric motor. In other instances, high winds may create a windmillingeffect or reverse rotation of a fan coupled to the electric motor. Thisreverse rotation may create a load with large inertia that can becomelarge enough to prevent the motor from starting and/or may damage thecomponents of the electric motor.

BRIEF DESCRIPTION

In one aspect, a method of controlling an electric motor using a motorcontroller including a processor is provided. The method includestransmitting, by the processor, a no-spin signal commanding the electricmotor not to spin, receiving temperature information associated with atemperature of the electric motor, comparing the temperature informationto a predetermined threshold temperature to determine whether thetemperature is at a sufficient level to prevent icing, and adjustingcurrent applied to the electric motor when the temperature measurementis below the predetermined threshold.

In another aspect, a motor controller coupled to an electric motor isprovided. The motor controller is configured to: transmit a no-spinsignal commanding the electric motor not to spin, receive temperatureinformation associated with a temperature of the electric motor, comparethe temperature information to a predetermined threshold temperature todetermine whether the temperature is at a sufficient level to preventicing, and adjust current applied to the electric motor when thetemperature information is below the predetermined threshold.

In a further aspect, an electric motor system is provided. The systemincludes an electric motor and a motor controller coupled to theelectric motor. The motor controller is configured to: transmit ano-spin signal commanding the electric motor not to spin, receivetemperature information associated with a temperature of the electricmotor, compare the temperature information to a predetermined thresholdtemperature to determine whether the temperature is at a sufficientlevel to prevent icing, and adjust current applied to the electric motorwhen the temperature information is below the predetermined threshold.

In yet a further aspect, a motor controller coupled to an electric motoris provided. The motor controller is configured to apply a first amountof current to windings of the electric motor, determine whether theelectric motor is operating, and apply a second amount of current to thewindings, wherein the second amount of current is larger than the firstamount of current.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an exploded view of an exemplary motor.

FIG. 2 is a schematic diagram of an exemplary motor controller for usewith the motor shown in FIG. 1.

FIG. 3 is a flowchart of an exemplary method of controlling the electricmotor shown in FIG. 2.

FIG. 4 is a flowchart of an exemplary method of controlling the electricmotor shown in FIG. 2.

FIG. 5 is a flowchart of an exemplary method of starting the electricmotor shown in FIG. 2.

FIG. 6 is a flowchart of an exemplary method of starting the electricmotor shown in FIG. 2.

FIG. 7 is a flowchart of an exemplary method of starting the electricmotor shown in FIG. 2.

FIG. 8 is a flowchart of an exemplary method of starting the electricmotor shown in FIG. 2.

DETAILED DESCRIPTION

FIG. 1 is an exploded view of an exemplary electric motor 10. Motor 10includes a stationary assembly 12 including a stator or core 14 and arotatable assembly 16 including a permanent magnet rotor 18 and a shaft20. In the exemplary embodiment, motor 10 is used in a heating,ventilating and air conditioning system (not shown).

Rotor 18 is mounted on and keyed to shaft 20 for rotation withinconventional bearings 22. Bearings 22 are mounted in bearing supports 24integral with a first end member 26 and a second end member 28. Firstend member 26 has an inner facing side 30 and an outer side 34. Secondend member 28 has an inner facing side 32 and an outer side 36. Outersides 34 and 36 are opposite inner sides 30 and 32 respectively.Stationary assembly 12 and rotatable assembly 16 are located betweensides 30 and 32. Additionally, second end member 28 includes an aperture38 for shaft 20 to extend through outer side 34.

Rotor 18 comprises a ferromagnetic core 40 and is rotatable withinstator 14. Segments 42 of permanent magnet material, each providing arelatively constant flux field, are secured, for example, by adhesivebonding to rotor core 40. Segments 42 are magnetized to be polarizedradially in relation to rotor core 40 with adjacent segments 42 beingalternately polarized as indicated. While magnets on rotor 18 areillustrated for purposes of disclosure, it is contemplated that otherrotors having different constructions and other magnets different inboth number and construction, and flux fields may be utilized with suchother rotors within the scope of the invention.

Stationary assembly 12 comprises a plurality of windings 44 adapted tobe electrically energized to generate an electromagnetic field. Windings44 are coils of wire wound around teeth 46 of laminated stator core 14.Winding terminal leads 48 are brought out through an aperture 50 infirst end member 26 terminating in a connector 52. While stationaryassembly 12 is illustrated for purposes of disclosure, it iscontemplated that other stationary assemblies of various otherconstructions having different shapes and with different number of teethmay be utilized within the scope of the invention.

Motor 10 may include any even number of rotor poles and the number ofstator poles are a multiple of the number of rotor poles. For example,the number of stator poles may be based on the number of phases.

Motor 10 further includes an enclosure 54 which mounts on the rearportion of motor 10. A control system 11 includes a plurality ofelectronic components 58 and a connector (not shown) mounted on acomponent board 60, such as a printed circuit board. Control system 11is connected to winding stages 44 by interconnecting connector 52.Control system 11 applies a current to one or more of winding stages 44at a time for commutating windings 44 in a preselected sequence torotate rotatable assembly 16 about an axis of rotation.

A housing 72 is positioned between first end member 26 and second endmember 28 to facilitate enclosing and protecting stationary assembly 12and rotatable assembly 16.

In one embodiment, at least one temperature sensor 74 is coupled tomotor 10 and is in communication with control system 11. Temperaturesensor 74 is configured to measure a temperature of the environment inwhich it is positioned and to transmit a signal to control system 11indicative of the measured temperature.

FIG. 2 is a schematic diagram of an exemplary motor controller 200 foruse with a motor 202, such as motor 10 (shown in FIG. 1). In theexemplary embodiment, motor controller 200 is an integrated component ofmotor 202, such as control system 11. Alternatively, motor controller200 may be communicatively coupled to motor 202 such that motorcontroller 200 is not integrated into motor 202. In one embodiment,motor controller 200 may control any number of motors as describedherein. In the exemplary embodiment, motor 202 is utilized as a fanand/or blower motor in a fluid (e.g., water, air, etc.) moving system infreezing temperatures, for example, as low at −50° C. Alternatively,motor 202 may be implemented in any application that enables electricmotor controller 200 to function as described herein, including, but notlimited to, a clean room filtering system, a fan filter unit, a variableair volume system, a refrigeration system, a furnace system, an airconditioning system, and/or a residential or commercial heating,ventilation, and air conditioning (HVAC) system.

Motor controller 200 controls motor 202 by transmitting a command signalto components of motor 202. In the exemplary embodiment, the commandsignal is one or more high-voltage and high frequency pulses. Motorcontroller 200 includes at least one memory device 204 and a processor206 that is communicatively coupled to memory device 204 for executinginstructions. In one embodiment, memory device 204 and processor 206 areintegrated into a single unit. In some embodiments, executableinstructions are stored in memory device 204. In the exemplaryembodiment, motor controller 200 performs one or more operationsdescribed herein by programming processor 206. For example, processor206 may be programmed by encoding an operation as one or more executableinstructions and by providing the executable instructions in memorydevice 204. Motor controller 200 also includes an input/output unit 208that enables input and output of data with other components within motor202 and/or devices that may be connected to motor controller 200. In oneembodiment, input/output unit 208 may provide a connection that enablesuser input to be transmitted and/or received through a user input device(not shown).

In the exemplary embodiment, memory device 204 is one or more devicesthat enable information such as executable instructions and/or otherdata to be stored and retrieved. Memory device 204 may include one ormore computer readable media, such as, without limitation, dynamicrandom access memory (DRAM), static random access memory (SRAM), a solidstate disk, and/or a hard disk. Memory device 204 may be configured tostore, without limitation, application source code, application objectcode, source code portions of interest, object code portions ofinterest, configuration data, execution events and/or any other type ofdata. In the exemplary embodiment, memory device 204 includes firmwareand/or initial configuration data for motor controller 200.

Processor 206 may include one or more processing units (e.g., in amulti-core configuration). Further, processor 206 may be implementedusing one or more heterogeneous processor systems in which a mainprocessor is present with secondary processors on a single chip.Alternatively, processor 206 may be a symmetric multi-processor systemcontaining multiple processors of the same type. Further, processor 206may be implemented using any suitable programmable circuit including oneor more systems and microcontrollers, microprocessors, reducedinstruction set circuits (RISC), application specific integratedcircuits (ASIC), programmable logic circuits, field programmable gatearrays (FPGA), and any other circuit capable of executing the functionsdescribed herein. In the exemplary embodiment, processor 206 controlsoperation of motor controller 200.

FIG. 3 is a flowchart of an exemplary method 300 of controlling electricmotor 202 (shown in FIG. 2). In the exemplary embodiment, motor 202and/or controller 200 receives 302 a stop command for electric motor 202to stop operating. In one embodiment, the stop command is received froma controller of an evaporator unit (not shown). Alternatively, the startcommand may be sent from any system and/or location that facilitatesstopping an electric motor as described herein. Generally, incold-storage applications, evaporator units will stop electric motor 202between 1 and 6 times per day to perform cycles through a condenser. Alarge amount of condensation occurs during the cycling and when theambient temperature is very cold (i.e., below freezing), ice formationmay occur while electric motor 202 is stopped.

In the exemplary embodiment, after receiving 302 the stop command, motorcontroller 200 transmits 304 a no-spin signal commanding electric motor202 not to spin. During the no-spin condition signal, motor controller200 continues applying 306 current to motor 202. In the exemplaryembodiment, motor controller 200 receives 308 a temperature reading froma temperature sensor coupled to motor 202, for example, temperaturesensor 74 (shown in FIG. 1). In one embodiment, temperature sensor 74 isa thermistor onboard motor 202 (i.e., in a power module or externaldevice). The temperature is inferred by monitoring the resistance of thethermistor. In another embodiment, temperature sensor 74 is an internaltemperature sensor of motor controller 200. In an alternativeembodiment, one or more temperature sensors 74 are coupled to motor 202inside and/or outside of housing 72 (shown in FIG. 1). Alternatively,the temperature may be inferred by estimating an impedance of stator 14.

In the exemplary embodiment, motor controller 200 compares 310 thetemperature reading to a predetermined threshold temperature todetermine whether the temperature is at a sufficient level to preventicing. If the temperature is above the predetermined threshold, motorcontroller 200 takes no action. If the temperature is below thepredetermined threshold, motor controller 200 adjusts 312 currentapplied to motor 202. More specifically, motor controller 200 increasesthe voltage to cause increased current to flow through motor windings 44(shown in FIG. 1), creating heat in motor 202. The voltage may be eitheran AC voltage or a DC voltage. Creating heat in motor 202 makes itharder for ice to form on both inside and outside of motor 202. The heatfurther causes an internal ambient temperature of the components housedwithin motor 202 to remain at a higher ambient temperature than theoutside environment.

In the exemplary embodiment, because the no-spin signal causes motor 202to not spin, motor controller 200 applies 314 current to only onewinding 44 of motor 202. More specifically, motor controller 200 appliesan amount of current to winding 44 based on the environment in whichmotor 202 is operating. For example, if motor 202 is going to be used inan environment where temperature is around −60° C., a sufficient amountof power should be applied to maintain motor 202 at −50° C. Given theamount of space available in motor 202, it may be necessary to apply anamount of current corresponding to a higher temperature (i.e., −20° C.)to maintain the temperature of motor 202 at −50° C.

In the exemplary embodiment, to adjust 312 current applied to motor 202,motor controller 200 determines an amplitude of the current output tomotor 202 based on a minimum external ambient temperature needed to beovercome, a target internal ambient temperature, and/or a unit size ofmotor 202. Bearing ratings and electronics ratings of motor 202 haveknown, limited values, so by keeping motor 202 above the predeterminedtemperature, exceeding the bearing and/or electronics ratings does notbecome an issue. Temperature limits of grease and bearings will not beexceeded, and in general, motor 202 will not lock up across mechanicalair gaps.

FIG. 4 is a flowchart of an exemplary method 400 of controlling electricmotor 202 (shown in FIG. 2). In the exemplary embodiment, method 400 issimilar to method 300 (shown in FIG. 3), except that method 400 appliescurrent to at least two phases of the windings of motor 202 to slightlymove or twitch motor 202, while method 300 applies voltage to only 1phase of motor windings 44. That is, in the exemplary embodiment, motor202 and/or controller 200 receives 402 a stop command for motor 202 tostop operating.

In the exemplary embodiment, after receiving 402 the stop command, motorcontroller 200 transmits 404 a no-spin signal commanding electric motor202 not to spin. During the stop command, motor controller 200 continuesapplying 406 current to motor 202. In the exemplary embodiment, motorcontroller 200 receives 408 a temperature reading from a temperaturesensor coupled to motor 202, for example, temperature sensor 74 (shownin FIG. 1). In one embodiment, temperature sensor 74 is coupled to motorcontroller 200. In an alternative embodiment, one or more temperaturesensors 74 are coupled to motor 202 inside and/or outside of housing 72(shown in FIG. 1). Alternatively, the temperature may be estimated usinga resistance of stator 14 rather than using temperature sensor 74.

In the exemplary embodiment, motor controller 200 compares 410 thetemperature reading to a preset threshold temperature to determinewhether the temperature is at a sufficient level to prevent icing. Ifthe temperature is above the predetermined threshold, motor controller200 takes no action. If the temperature is below the predeterminedthreshold, motor controller 200 adjusts 412 current applied to motor202. More specifically, motor controller 200 increases the voltage tocause increased current to flow through the motor windings, creatingheat in motor 202. The voltage may be either an AC voltage or a DCvoltage. Creating heat in motor 202 makes it harder for ice to form onboth the inside and the outside of motor 202. The heat further causesthe internal ambient temperature of the components housed within motor202 to remain at a higher ambient temperature than the outsideenvironment.

In the exemplary embodiment, motor controller 200 applies 414 current toat least two phases of the motor windings, causing motor 202 to twitch(i.e., 1/120^(th) of 360 degrees every few seconds). By applying currentto at least two phases of the motor windings, the energized phasesperiodically transition in order to slightly rotate the motor rotorassembly to prevent ice formation. A twitch frequency is adjustable forthe specific application. Motor controller 200 determines the twitchfrequency based on a minimum temperature, a condensation/humidity level,and/or a unit size of motor 202. Motor controller 200 may change thetwitch frequency based on a lookup table associated with the specificapplication or motor controller 200 may cycle through a predeterminedrange of twitch frequencies until the proper frequency for preventingice formation is found. Applying current to two or more windings totwitch motor 202 may be desirable when there are smaller gaps betweenthe mechanical parts. When a small amount of movement is introduced, itbecomes harder for ice to form across those gaps.

FIG. 5 is flowchart of an exemplary method 500 of starting electricmotor 202 (shown in FIG. 2). In the exemplary embodiment, method 500 isimplemented on motor 202 after an ice buildup has occurred. Motor 202and/or motor controller 200 receives 502 a start command for motor 202to begin operating. In one embodiment, the start command is receivedfrom a controller of an evaporator unit (not shown). Alternatively, thestart command may be sent from any system and/or location thatfacilitates starting an electric motor as described herein.

In the exemplary embodiment, after receiving 502 the start command,controller 200 momentarily applies 504 current to windings 44 (shown inFIG. 1) to increase a winding coil temperature. In one embodiment,controller 200 waits a predetermined amount of time after applying 504the current. The predetermined amount of time can be any amount of timethat facilitates starting a motor as described herein, including but notlimited to 5-30 seconds. In one embodiment, controller 200 determines506 if motor 202 is operating by comparing measured operating RPMs ofmotor 202 to a predetermined RPM threshold. Motor controller 200 isconfigured to determine that electric motor 202 is operating when themeasured RPM of the electric motor exceed the predetermined RPMthreshold.

If controller 200 determines that motor 202 is operating, controller 200operates motor 202 in a normal run mode. If controller 200 determinesthat motor 202 is not operating, controller 200 momentarily applies 508a higher current to windings 44 (shown in FIG. 1) to increase thewinding coil temperature. The steps of applying current to windings 44and determining if motor 202 is operating are repeated until the icebuildup is melted and motor 202 is operational.

FIG. 6 is a flowchart of an exemplary method 600 of starting electricmotor 202 (shown in FIG. 2). Out on rooftops, sometimes a fan coupled tomotor 202 is blown and rotates in an opposite direction of the desireddirection. When the unit is called to start-up, there is so much torquespinning in the opposite direction that motor 202 struggles to start.Method 600 overcomes reverse spinning by using a brake to stop the fanand then injecting a much higher amount of current than for a normalstart. Motor electronics are typically started with a minimum amount ofcurrent to try to extend the life of the product, but the minimumcurrent is not nearly enough to stop backwards windmilling.

In the exemplary embodiment, motor 202 and/or motor controller 200receives 602 a start command for motor 202 to begin operating. In oneembodiment, the start command is received from a controller of anevaporator unit (not shown). Alternatively, the start command may besent from any system and/or location that facilitates starting anelectric motor as described herein. In the exemplary embodiment, afterreceiving 602 the start command, controller 200 determines 604 if motor202 is rotating backwards using known techniques. More specifically, inthe exemplary embodiment, controller 200 initiates a normal startroutine by injecting a low current into windings 44 (shown in FIG. 1).After at least one failed forward start attempt of motor 202, motorcontroller 200 assumes 604 a reverse start command to help overcomeunknown rotor position and rotor rotation direction during a low speedwind mill condition.

When reverse rotation is determined 604, controller 200 applies and/orinitiates 606 a reverse rotation start routine. The reverse rotationstart routine includes applying 608 a brake to motor 202 and injecting610 a large current into motor 202. In this embodiment, braking 608 isachieved by controller 200 short circuiting windings (e.g. windingstages 44 shown in FIG. 1). In another embodiment, braking 608 isachieved by controller 200 modulating a braking torque.

In one embodiment, the reverse rotation start routine brakes motor 202,and injects 610 a much larger current into motor 202 than for normalstarting to increase the torque of the normal start routine by apredetermined amount or percentage. The amount of current injected isset to a maximum amount based on the electronic limits of the powermodule in motor 202. Alternately, the amount of current may be increasedfor each attempt to brake motor 202, which would be easier on theelectronics and harder on the equipment that includes the motor. Inanother embodiment, the reverse rotation start routine utilizes a lastknown start routine, brakes the motor, and increases the torque for thatstart routine by a predetermined amount or percentage. In yet anotherembodiment, the reverse rotation start routine brakes rotation of themotor and applies and/or initiates the normal start routine.

In the exemplary embodiment, after the reverse rotation start routine isinitiated 606, controller 200 determines 612 if motor 202 is operating.If motor 202 is determined to be operating, motor controller 200operates motor 202 in a normal operating mode. If motor 202 isdetermined not to be operating, the process loop continues untiloperation of motor 202 is determined.

FIG. 7 is a flowchart of an exemplary method 700 of starting electricmotor 202 (shown in FIG. 2). Method 700 is similar to method 600 (shownin FIG. 6), but further includes use of motor 202 as a brake to create aknown stop prior to starting against back pressure/wind.

In the exemplary embodiment, motor 202 and/or motor controller 200receives 702 a start command for motor 202 to begin operating. In oneembodiment, the start command is received from a controller of anevaporator unit (not shown). Alternatively, the start command may besent from any system and/or location that facilitates starting anelectric motor as described herein. In the exemplary embodiment, afterreceiving 702 the start command, controller 200 determines 704 if motor202 is rotating backwards using known techniques. More specifically, inthe exemplary embodiment, controller 200 initiates a normal startroutine by injecting a small, first amount of current into windings 44(shown in FIG. 1).

When reverse rotation is determined, controller 200 applies and/orinitiates 706 a reverse rotation start routine. The reverse rotationstart routine includes, after injecting the first amount of current intowindings 44, applying a brake 708 to motor 202. In this embodiment,braking 708 is achieved by controller 200 short circuiting windings(e.g. winding stages 44 shown in FIG. 1). In another embodiment, braking708 is achieved by controller 200 modulating a braking torque.Controller 200 then determines 710 if motor 202 is still operating in areverse rotation direction. If motor 202 is operating in a reverserotation direction, controller 200 injects 712 the first amount ofcurrent into windings 44 again and applies 714 a brake to motor 202.

In one embodiment, controller 200 waits either a predetermined timeperiod or a predetermined number of forward rotation attempts afterinjecting 712 the first amount of current to the windings. Thepredetermined amount of time may be any amount of time that facilitatesstarting a motor as described herein, including but not limited to 5-30seconds. The predetermined number of forward rotation attempts may beany number of attempts that facilitates starting a motor as describedherein, for example, greater than one.

Controller 200 then injects 716 a much larger, second amount of currentinto motor 202 than for normal starting to increase the torque of thenormal start routine by a predetermined amount or percentage. The secondamount of current injected is set to a maximum amount based on theelectronic limits of the power module in motor 202. Applying 716 thesecond amount of current into motor 202 further includes controller 200accelerating a load coupled to motor 202. Alternately, the amount ofcurrent may be increased for each attempt to brake motor 202, whichwould be easier on the electronics and harder on the equipment it is in.In another embodiment, the reverse rotation start routine utilizes alast known start routine, brakes the motor, and increases the torque forthat start routine a predetermined amount or percentage. In yet anotherembodiment, the reverse rotation start routine brakes rotation of themotor and applies and/or initiates the normal start routine.

In the exemplary embodiment, after the reverse rotation start routine isapplied and/or initiated 706, controller 200 determines 718 if motor 202is operating. If motor 202 is determined to be operating, the motorcontroller 200 operates motor 202 in a normal operating mode. If motor202 is determined not to be operating, the process loop continues untiloperation of motor 202 is determined. By using a brake between eachstart attempt to try to stop the windmilling prior to starting, thewindmilling is brought to a lower speed, so there is less force thanwhen trying to start straight against higher RPMs.

FIG. 8 is flowchart of an exemplary method 800 for starting electricmotor 202 (shown in FIG. 2). Method 800 is applied to fracture iceparticles that cause a locked rotor condition. Method 800 has the mostimpact on ice buildup when motor 202 is locked and trying to start.

In the exemplary embodiment, motor 202 and/or controller 200 receives802 a start command for motor 202 to begin operating. In one embodiment,the start command is received from a controller of an HVAC system.Alternatively, the start command can be sent from any system and/orlocation that facilitates starting an electric motor as describedherein. In the exemplary embodiment, after receiving 802 the startcommand, controller 200 injects 804 current having a first frequencyinto the windings.

In the exemplary embodiment, after current having a first frequency isinjected 804, controller 200 determines 806 if motor 202 is operating.If motor 202 is determined to be operating, motor controller 200operates motor 202 in a normal operating mode. If motor 202 isdetermined not to be operating, controller 200 injects 808 currenthaving a second frequency into the windings. Changing the frequency ofthe current generates vibrations in motor 202, which breaks up the iceformation. The frequency of the current correlates to vibrations inducedin the rotor. By changing the frequency, the rotor shakes faster orslower to break the ice. Based on the frequency of the inverter,controller 200 may form a square wave and range from a few Hz to a fewkHz of the switching frequency that prevents ice buildup.

In the exemplary embodiment, after current having a second frequency isinjected 808, controller 200 determines 810 if motor 202 is operating.If motor 202 is determined to be operating, motor controller 200operates motor 202 in a normal operating mode. If motor 202 isdetermined not to be operating, the process loop continues untiloperation of motor 202 is determined.

In the exemplary embodiment, injecting current having the first and/orsecond frequency may include sweeping a range of frequencies, applyingfrequency patterns, and/or executing an algorithm that applies afrequency and measures relative motion in a closed loop fashion.

The embodiments described herein provide systems and methods forstarting an electric motor that may be operating in a reverse rotation.The embodiments facilitate overcoming or preventing no-start conditionsand extend product life of electric motors used in extreme cold,condensation/humidity, and back pressure/windmill environments. Thesystems and methods described herein enable a motor to prevent motorlock up due to ice formation in its air gaps and to preventcondensation/rust formation within the motor. The systems and methodsdescribed herein further enable a motor to start during windmilling atboth low and high RPMs as well as when there is an uneven formation ofice on an unmoving fan. The embodiments described herein also enable acontroller to detect reverse or windmilling rotation without the use ofposition sensors, which reduces cost of production and increasesreliability of the systems.

Exemplary embodiments of the control system and methods of controllingan electric motor are described above in detail. The control system andmethods are not limited to the specific embodiments described herein,but rather, components of the control system and/or the motor and/orsteps of the method may be utilized independently and separately fromother components and/or steps described herein. For example, the controlsystem and methods may also be used in combination with other powersystems and methods, and are not limited to practice with only the HVACsystem as described herein. Rather, the exemplary embodiments can beimplemented and utilized in connection with many other systemapplications or other support.

A technical effect of the system described herein includes at least oneof: a) transmitting, by the processor, a no-spin signal commanding theelectric motor not to spin; b) receiving, by the processor, temperatureinformation associated with a temperature of the electric motor; c)comparing, by the processor, the temperature information to apredetermined threshold temperature to determine whether the temperatureis at a sufficient level to prevent icing; and d) adjusting, by theprocessor, current applied to the electric motor when the temperatureinformation is below the predetermined threshold.

Although specific features of various embodiments of the invention maybe shown in some drawings and not in others, this is for convenienceonly. In accordance with the principles of the invention, any feature ofa drawing may be referenced and/or claimed in combination with anyfeature of any other drawing.

This written description uses examples to disclose the invention,including the best mode, and also to enable any person skilled in theart to practice the invention, including making and using any layers orsystems and performing any incorporated methods. The patentable scope ofthe invention is defined by the claims, and may include other examplesthat occur to those skilled in the art. Such other examples are intendedto be within the scope of the claims if they have structural elementsthat do not differ from the literal language of the claims, or if theyinclude equivalent structural elements with insubstantial differencesfrom the literal language of the claims.

What is claimed is:
 1. A motor controller coupled to an electric motorconfigured to drive a fluid moving apparatus coupled to the electricmotor in a first rotation direction, the motor controller configured to:determine whether the fluid moving apparatus coupled to the electricmotor is spinning in a reverse rotation direction before starting theelectric motor; and initiate a reverse rotation start routine when thefluid moving apparatus coupled to the electric motor is determined to bespinning in the reverse rotation direction, the reverse rotation startroutine comprising: applying a brake to the electric motor; and applyinga first amount of current to windings of the electric motor afterapplying the brake.
 2. The motor controller of claim 1, wherein todetermine whether the fluid moving apparatus coupled to the electricmotor is spinning in the reverse rotation direction, the motorcontroller is further configured to: initiate a normal start routinecomprising injecting a second amount of current to the windings of theelectric motor, the second amount of current less than the first amountof current; and determine the normal start routine has failed.
 3. Themotor controller of claim 1, wherein to apply the brake to the electricmotor, the motor controller is further configured to short circuit thewindings of the electric motor.
 4. The motor controller of claim 1,wherein to apply the brake to the electric motor, the motor controlleris further configured to modulate a braking torque.
 5. The motorcontroller of claim 1, wherein the reverse rotation start routine is afirst reverse rotation start routine, and wherein the motor controlleris configured to: determine the fluid moving apparatus coupled to theelectric motor is spinning in the reverse rotation direction after thefirst reverse rotation start routine; and initiate a second reverserotation start routine comprising: applying the brake to the electricmotor; and applying a second amount of current to the windings of theelectric motor after applying the brake, the second amount of currentgreater than the first amount of current.
 6. The motor controller ofclaim 1, wherein the motor controller is further configured to receive astart command before determining whether the fluid moving apparatuscoupled to the electric motor is spinning in the reverse rotationdirection.
 7. The motor controller of claim 1, wherein the motorcontroller is further configured to: wait at least one of apredetermined time period or a predetermined number of forward rotationattempts after applying the first amount of current to the windings; andapply a second amount of current to the windings, wherein the secondamount of current is larger than the first amount.
 8. The motorcontroller of claim 7, wherein the predetermined time period is betweenabout 5 seconds and 30 seconds, and wherein the predetermined number offorward rotation attempts is greater than one.
 9. The motor controllerof claim 7, wherein, when applying the second amount of current to thewindings, the motor controller is further configured to accelerate thefluid moving apparatus coupled to the electric motor.
 10. A motorcontroller coupled to an electric motor and configured to: transmit ano-spin signal commanding the electric motor not to spin; continuouslyapply voltage to the electric motor while the electric motor is notspinning in response to the no-spin signal; receive temperatureinformation associated with a temperature of the electric motor; comparethe temperature information to a predetermined threshold temperature todetermine whether the temperature is at a sufficient level to preventicing; and when the temperature information is below the predeterminedthreshold, adjust the voltage applied to the electric motor to increaseinduced current therein while the electric motor is not spinning inresponse to the no-spin signal to maintain the temperature of theelectric motor at the sufficient level to prevent icing.
 11. The motorcontroller of claim 10, wherein to receive temperature information, saidmotor controller is further configured to at least one of receivetemperature information from a temperature sensor coupled to theelectric motor or generate a temperature estimation.
 12. The motorcontroller of claim 10, wherein to adjust the voltage applied to theelectric motor, said motor controller is further configured to determinean amplitude of the current to apply to the electric motor based on atleast one of a minimum external ambient temperature needed to beovercome, a target internal ambient temperature, or a unit size of theelectric motor.
 13. The motor controller of claim 10, further configuredto apply current to only one phase of a plurality of phases of motorwindings associated with the electric motor.
 14. The motor controller ofclaim 10, further configured to transmit the no-spin signal in responseto receiving a stop signal.
 15. A motor controller coupled to anelectric motor and configured to: transmit a no-spin signal commandingthe electric motor not to spin; continuously apply voltage to theelectric motor while the electric motor is not spinning in response tothe no-spin signal; receive temperature information associated with atemperature of the electric motor; compare the temperature informationto a predetermined threshold temperature to determine whether thetemperature is at a sufficient level to prevent icing; and when thetemperature information is below the predetermined threshold, adjust thevoltage applied to the electric motor to increase induced currenttherein while the electric motor is not spinning in response to theno-spin signal to cause movement in the electric motor to prevent icing.16. The motor controller of claim 15, wherein to adjust the voltageapplied to the electric motor, said motor controller is furtherconfigured to induce current in at least two phases of a plurality ofphases of motor windings associated with the electric motor.
 17. Themotor controller of claim 16, wherein to apply the voltage to the atleast two phases, said motor controller is further configured to inducecurrent in at least two phases at a twitch frequency to twitch theelectric motor to prevent ice formation.
 18. The motor controller ofclaim 17, wherein said motor controller is further configured todetermine the twitch frequency based on at least one of a minimumtemperature, a condensation level, or a unit size of the electric motor.19. The motor controller of claim 15, wherein to receive temperatureinformation, said motor controller is further configured to receivetemperature information from a temperature sensor coupled to theelectric motor.
 20. The motor controller of claim 15, wherein to receivetemperature information, said motor controller is further configured togenerate a temperature estimation.